Brassiere

ABSTRACT

A molded brassiere having a core of a first foam layer and a second foam layer laminated to each other with underwire interposed. An outer fabric layer extends beyond the core forming at least part of the chest bands. The bridge between the cups optionally includes a flexible non-stretchable material.

PRIORITY CLAIM

This is a continuation-in-part of U.S. patent Ser. No. 10/864,255, filed Jun. 8, 2004, which is know U.S. Publication Number US2004/0224604 published on Nov. 11, 2004, which is a continuation-in-part of U.S. patent Ser. No. 10/349,514, filed Jan. 21, 2003, which is know U.S. Publication Number US 2004/0142633 published on Jul. 22, 2004.

FIELD OF THE INVENTION

The present invention relates to brassieres and in particular to a brassiere which incorporates a seamless breast cup construction and wherein an appealing outward appearance is provided.

BACKGROUND TO THE INVENTION

Construction details of brassieres (hereinafter referred to as “bras”) have been developed over many years. Construction details have evolved along with the introduction of new materials and new processes which can be utilised for the manufacturing of bras. As with most consumer products, manufacturers endeavour to reduce the cost of goods sold. A reduction in cost of goods sold can be brought about by the use of cheaper materials. For bra technology however, a significant saving in the cost of a bra can be achieved by eliminating the man-hours required to manufacture the bra. Many bras that are available on the market will include multiple panels of materials which need to be cut, and joined. Cutting can be automated, however when it comes to stitching the panels together, this will mostly be done by a person. The breast cup of a bra may consist of multiple panels which each need to be stitched together, the entire breast cup then needs to be stitched to the chest band and to the over the shoulder straps. Perimeter stitching or overlooking to ensure that the edges of the material of the bra do not fray also needs to be added to the bra. Such is also done by a person. It can hence be seen that in order to manufacture a bra, the labour component of the overall cost can be relatively high.

Bras that incorporate breast support pads are also known. Such pads may be defined by foam pads incorporated within layers of the bra so that they are not at the perimeter edges. This is a disadvantage as it may provide a bra that is visually unappealing.

Accordingly it is an object of the present invention to provide a seamless breast cup construction which addresses the above disadvantages or will at least provide the public with a useful choice.

It is also an object of the present invention to provide a method of manufacturing a seamless breast cup construction and related bra incorporating such construction to reduce the labour content of manufacturing of the bra or to at least provide the public with a useful choice.

BRIEF DESCRIPTION OF THE INVENTION

Accordingly in a first aspect the present invention consists in a brassiere comprising:

a core defining at least two breast cups of the brassiere, the core comprising a first layer of foam material, a second layer of foam material that is substantially laminated with the first layer of foam material, and an underwire located between the first and second layers of foam material at or adjacent the lower peripheral part of one or each of the two breast cups; and

a first and a second covering layer, each covering layer comprising at least a fabric ply and each covering layer being laminated with the core on a respective side of the core to encase the core.

Preferably the core has been subjected to molding to form the shape of the two breast cups.

Preferably the core does not define any chest band of the brassiere.

Preferably one or each of the first and second layers of foam material is a continuous layer extending across the core.

Preferably the underwire comprises a rigid elongate member and a channel encasing the rigid elongate member.

Preferably the channel is a fabric material.

Preferably the first and second layers of foam material have mutually facing surfaces and the channel is adhered to one or each of the facing surfaces of the first and second layers of foam material by an adhesive.

Preferably the underwire is a non-metallic strip.

Preferably the core has a perimeter and one or each of the first and second covering layers extends beyond at least a portion of the perimeter of the core to form at least part of a chest band of the brassiere.

Preferably the first covering layer comprises a fabric ply and a foam ply, the fabric ply and the foam ply being laminated to each other.

Preferably a surface of the core is laminated to the foam ply of the first covering layer.

Preferably the second layer of foam material is laminated to the first layer of foam material by an adhesive.

Preferably the core further defines a bridge between the two breast cups, and wherein a flexible and substantially non-stretchable panel of material is located between the first and second layers of foam material and laminated with one or each of the first and the second layers of foam material at the bridge.

Preferably the core has a perimeter and the brassiere further comprises an outermost layer that is more away from the body of the wearer of the brassiere than either of the first and the second covering layers, the outermost layer extending beyond at least a portion of the perimeter of the core to form at least part of a chest band of the brassiere.

Preferably the brassiere has an inner surface and the outermost layer has a perimeter, the outermost layer being folded at at least a portion of its perimeter to provide a hem affixed to at least a portion of the inner surface of the brassiere.

Preferably the hem is affixed to at least a portion of the perimeter region of the inner surface of the brassiere.

Preferably one of the first and second covering layers is at least part of the inner surface of the brassiere.

Preferably the brassiere further comprises a strip of fabric material that is affixed to at least a portion of the hem and at least a portion of the inner surface of the brassiere.

Preferably the outermost layer includes a lace fabric.

Preferably the hem is affixed adhesively to at least a portion of the inner surface of the brassiere.

Preferably the outermost layer is not laminated to at least one of the first and second covering layers.

Preferably the core further comprises a pouch located between the first and second layers of foam material at or adjacent a lower portion of one or each of the two breast cups, the pouch containing a material selected from one of a liquid and a gel.

Preferably the pouch is laminated to one or each of the first and second layers of foam material.

In a further aspect the present invention consists in a brassiere comprising:

a core having a perimeter and defining at least two molded breast cups of the brassiere, the core comprising an outer layer of foam material, an inner layer of foam material that is substantially laminated with the outer layer of foam material, and an underwire interposed between the outer and inner layers of foam material at or adjacent the lower peripheral part of one or each of the two breast cups;

an outer and an inner covering layer, each covering layer comprising a fabric ply and a foam ply which are substantially laminated to each other, the foam ply of each covering layer being substantially laminated with the core on a respective side of the core to encase the core; and

wherein one or each of the outer and inner covering layers extends beyond at least a portion of the perimeter of the core to form at least part of a chest band of the brassiere.

Preferably the core further comprises a pouch located between the outer and inner layers of foam material at or adjacent a lower portion of one or each of the two breast cups, the pouch containing a material selected from one of a liquid and a gel.

Preferably the brassiere further comprises an outermost layer that is at a greater distance from the body of the wearer of the brassiere than either of the outer and the inner covering layers, the outermost layer extending beyond at least a portion of the perimeter of the core to form at least part of a chest band of the brassiere.

Preferably the brassiere is seamless.

BRIEF DESCRIPTION OF THE DRAWINGS

A preferred embodiment of the present invention will now be described with reference to the accompanying figures.

FIG. 1 is a front view of a brassiere (hereinafter referred to as a “bra”) made in accordance to methods hereinafter described,

FIG. 2 is a plan view of two layers of precursor material, the upper being a foam material and the lower being a fabric material to be laminated together,

FIG. 3 is a plan view of precursor layers of material, the upper being a foam material and the lower being a fabric material,

FIG. 4 illustrates the layers of FIG. 2 having been laminated together to define a precursor outer assembly by the use of, for example, an adhesive and/or heat lamination,

FIG. 5 is a perspective view of the layers of FIG. 3 having been laminated together to define a precursor outer assembly wherein the lamination has been achieved by an adhesive and/or heat lamination,

FIG. 6 is a perspective view of an underwire assembly to be incorporated in the bra of the present invention,

FIG. 7 is a sectional view through Section AA of FIG. 6,

FIG. 8 is a sectional view through Section BB of FIG. 6,

FIG. 9 is a plan view of a precursor layer of material of foam,

FIG. 10 is a plan view of another precursor layer of foam material,

FIG. 11 is a plan view of a precursor fabric panel,

FIG. 12 is a sectional view through a molding device consisting of an upper and lower mold intermediate of which an assembly of the layers of FIGS. 9, 10 and 11 and the underwire assembly are placed for the simultaneous molding and lamination thereof to define a molded core assembly capturing within the assembly the underwire assemblies underneath or adjacent of each of the cups mold formed in the layers,

FIG. 13 is a sectional view through the two cup forms of the assembly of layers shown in FIG. 12 after the mold forming and lamination thereof,

FIG. 14 is a plan view of the flexible core assembly of FIG. 13 and wherein perimeter trimming has occurred to define a core assembly of layers,

FIG. 15 is a sectional view through a molding device providing upper and lower mold portions intermediate of which the flexible core assembly of FIG. 14 is placed and relative to which the core precursor panel assembly of FIGS. 4 and 5 are positioned for the subsequent mold forming and lamination of the plies together,

FIG. 16 is a plan view of the assembly of panels molded according to the molding process of FIG. 15 and wherein excess perimeter material has been trimmed,

FIG. 17 is a sectional view through Section CC of FIG. 16,

FIG. 18 shows a front view of part of a bra wherein the perimeter finishing of at least part of the bra is different to that described with reference to FIGS. 15 and 16,

FIG. 19 is a view of the components of the bra of FIG. 18 shown from the opposite direction,

FIG. 20 is a sectional view through section DD of FIG. 19,

FIG. 21 is a transparent front view of a core assembly wherein a pouch is provided at each breast cup,

FIG. 22 is a plan view of a pouch,

FIG. 23 shows a front view of part of a bra wherein a perimeter finishing of at least part of the bra is different to that described with reference to FIGS. 15 and 16,

FIG. 24 is a view of the components of the bra of FIG. 23 shown from the opposite direction, and

FIG. 25 is a sectional view through section EE of FIG. 24.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 shows a front view of a bra which has been manufactured according to a method as herein described.

The bra 1 consists of an assembly of panels that are joined together to define a single structure incorporating the chest bands 2 and two breast cups 3. The chest bands 2 may at their free ends 4, 5 be provided with mutually interactable catches or fasteners to allow for the free ends 4 and 5 to be engaged together. Also provided may be shoulder straps 6, 7 which are fixed to appropriate regions of the chest bands and to the breast cups to allow for such to have over the shoulder support for the wearer of a bra.

Such shoulder straps may however be optional as it is envisaged that the bra may be of a strapless version. Indeed, whilst reference is herein made to a bra, it is envisaged that the assembly of panels to define such may alternatively be incorporated into other garments such as, for example, evening dresses or bathing suits or the like.

Where reference herein is made to inward and outward or other similar terms, they are understood to be in relation to the body of the wearer of the bra. For example, the “inward” or “inner” side or region or thing is a relative term to denote that an item or a component of the bra is more proximate or closer to the body of the wearer of the bra than other items or components of the bra that are at a greater distance from the body of the wearer. “Outward” and “outer” are similarly interpreted. Additionally, “Inner” does not mean “inner most” unless otherwise specified. Similarly, “outer” does not mean “outer most” unless otherwise specified. Also, “exterior” does not mean inner or outer most unless otherwise specified.

“Seamless” is understood to mean that the bra is visibly substantially seamless, in that the edges of the bra are finished in a seamless or substantially seamless way, for example by ultrasonic welding, or by folding the edge of an outer layer over and affixing it to an inner layer by a non-stitching means, or by some other means that is substantially without seams. Seams may, however, be found inside the bra structure where it is not externally visible, or in a visibly less conspicuous external place such as the region where a shoulder strap is attached to a breast cup, or the region where a hook or eye tape is connected to the chest band.

Reference will now be made to a preferred method of construction (and variations thereof) which will explain preferred assemblies of panels which may be used to facilitate the manufacture of the bra of FIG. 1.

FIG. 2 shows two precursor layers, panels, sheets, or plies of material (hereinafter “layer”). The first layer 8 may be of a foam material, preferably of a thickness of 3.1 mm.

The second layer 9 may be a fabric material such as a fabric known by model number CMF-7440MU of Friendly Foundate Ltd. This fabric is made of 80% Tactel and 20% lycra. The fabric layer 9 may have a make-up of approximately 80% Tactel 40 d/ 34 f and 20% lycra 40 d and of a weight of, for example, 190 g/m2.

The foam is preferably a polyurethane foam of a density of, for example, 30-40 d.

With reference to FIG. 4, the foam panel 8 and the fabric panel 9 are laminated together (preferably but not necessarily over their entire contiguous surfaces) to provide a first covering panel assembly 10. It is to be understood that the first covering panel assembly is not necessarily an outermost or innermost layer of the bra. There may be other layer(s) or panel(s) covering the first covering panel assembly 10.

The first covering panel assembly 10 is also referred to as the outer panel assembly 10. “Outer” refers to the panel assembly 10 being at a greater distance from the body of the wearer of the bra than a core assembly 33 that will be described hereinafter.

The outer panel assembly 10 comprises the layer of foam 8 substantially laminated to the layer of fabric 9. The layers 8, 9 are preferably substantially co-extensive with each other and may have been laminated together using an adhesive such as glue HM-1 of Forbo Swift Adhesives SA. This glue will stick the fabric and foam together when dry without heating. It is sprayed onto at least one of the facing surfaces of the foam or fabric layers 8, 9. The surface of foam layer 8 that is not facing fabric layer 9 is also sprayed with a glue such as RM-30 of Ultra Energy Adhesive Trading Co., Ltd. This glue will dry without sticking but will stick when heated in the mold during the molding process shown in FIG. 15 and described hereinbelow. As an alternative to the foam layer 8 and fabric layer 9 being co-extensive, the foam layer may be smaller in size and positioned inward of the entire perimeter of the fabric layer 9.

Where a foam layer 8 is present in the outer panel assembly 10, it is at least of a size to overlap at least a substantial part, if not all, of a core assembly 33 that will be described hereinafter.

A variation to the aforesaid outer panel assembly 10 is possible where the outer panel assembly 10 comprises only one ply of material.

With reference to FIG. 3, there are shown a foam panel 11 and a fabric panel 12 which, like the foam panel 8 and fabric panel 9, are laminated (preferably but not necessarily over their entire contiguous surfaces) together to define a second covering panel assembly 13 as shown in FIG. 5. It is to be understood that the second covering panel assembly 13 is not necessarily an outermost or innermost layer of the bra. There may be other layer(s) or panel(s) covering the second covering panel assembly 13.

The second covering panel assembly 13 is also referred to as the inner panel assembly 13. “Inner” refers to the panel assembly 13 being at a smaller distance from the body of the wearer of the bra than the core assembly 33 and the outer panel assembly 10. The foam panel 11 is preferably of a foam such as EWA35 of Inoac Corporation which is a polyurethane and is of a thickness of 1.7 mm.

The fabric panel 12 is preferably of the same material as that of the fabric panel 9. The surface of foam panel 11 that is not facing fabric panel 12 may also be sprayed with a glue such as RM-30 of Ultra Energy Adhesive Trading Co., Ltd. As a variation to the inner panel assembly 13 as hereinbefore described, it may instead comprise only a single ply of fabric material. Where a foam panel 11 is present in the inner panel assembly 13, it is at least of a size to overlap at least part, if not all, of the core assembly 33.

The bra (and its core assembly 33 which will hereinafter be described) may incorporate an underwire structure 25. The underwire structure 25 may consist of a substantially rigid but to a certain extent flexible wire 20 which may be of a diameter of, for example, 2 mm as shown in FIG. 7. The wire may be made from a metallic material such as stainless steel. In that case, the wire is preferably captured within a sock or a channel 21. The sock or channel may be closed at each end 22, 23 as, for example, shown in FIG. 8. The sock or channel may be made from a fabric material or a material such as TRICOT. The closure of the end of the sock or channel 22, 23 may be achieved by using an ultrasonic machine to bond the sock or channel closed. The underwire structure 25 is then ready for subsequent incorporation.

As a variation to using a metallic underwire, the underwire structure 25 may alternatively be made up totally of non-metallic material. For example, the underwire structure can be the sock or channel 21 as described hereinbefore alone without the wire 20. Thus, a non-metallic underwire structure can for example be a fabric channel as conventionally used to encase a steel underwire for a conventional bra. After being subjected to molding with the foam layers 29 and 30, which will hereinafter be described, the conventional fabric channel embedded by the foam layers 29 and 30 will harden to a state whereby it will become a comfortable substitute for the conventional steel underwire. A non-metallic underwire structure is preferably of a strip form, substantially planar, and resiliently bendable. Compared with a metallic underwire, a non-metallic underwire structure enhances the softness of the bra making it more comfortable to wear. Any non-metallic resiliently bendable strip can be used as the underwire structure 25.

With reference to FIG. 9, there is shown a plan view of a layer of foam material 29. This may form the outer layer of a core assembly 33 for the bra. The foam layer 29 is preferably of a polyurethane foam/memory foam such as, for example, EL58-4S of Inoac Corporation which is a polyurethane/memory foam and is of a thickness of, for example, 6 mm.

The core assembly 33 is also referred to simply as the core.

FIG. 10 is a plan view of a layer of foam 30 which may form the inner layer of the core 33. The foam layer 30 is made of a polyurethane foam/memory foam such as, for example, EL58-4S of Inoac Corporation. It is preferably of a thickness of approximately 6 mm. The foam layers 29 and 30 are laminated together such as by the method hereinafter described.

In FIG. 11 there is shown a plan view of a layer or panel of fabric material 31 which may optionally be incorporated as part of the core 33.

The fabric layer 31 is for example fabric 7118 of Goldspring Co. Ltd. It is preferably a piece of gauze which is 100% nylon. This layer is included in the core 33 between the two foam layers 29 and 30 of the core. The fabric layer 31 may be provided to be interposed between the foam layers 29 and 30 at a bridge region 41 of the core 33, the bridge being intermediate of the two breast cups 39 and 40. The fabric layer 31 is to be laminated into the core 33, and is preferably located between the two breast cups 39 and 40. It provides resistance against the elasticity which may otherwise be resultant at the bridge region 41 between the breast cups. It reduces the elasticity of the core 33 at the region between the breast cups. The layer 31 is substantially non-stretchable but is flexible in a manner to allow it to bend. It may consist of a single ply or multi ply assembly. It is desirable to ensure that the breast cups remain at a substantially constant disposition relative to each other. In the most preferred form, such a fabric layer 31 does not extend to the region below the breast cups, and merely extends at the region which bridges the breast cups 39, 40. At such bridge region 41, the foam layers 29 and 30 are also provided.

Each of the sides of the panels or layers 31, 29 and 30 that are to be laminated (and also the sock or channel 21 of the underwire structure 25 which is preferably provided) are sprayed with an adhesive whereupon they are assembled but still remaining in a planar form. Two underwire structures 25, preferably provided, are positioned between the foam layers 29 and 30 at appropriate location (preferably the lower peripheral part) of the breast cups to be formed. The cup forms are then molded into the assembly of layers and components to define the core 33. Additional, or substitute, plies or components may optionally be incorporated into the core 33 before molding.

Molding of the core 33 may then occur by the mold portions 34, 35. The mold portions 34, 35 have surface relief provided thereto for the purposes of molding and introducing two cup forms into the layers of the core 33. The upper mold 34 is preferably of a temperature of 180° C. to 200° C. and the lower mold is preferably of 180° C. to 200° C. The dwell time holding the mold portions together is preferably 120 seconds.

With reference to FIG. 13, there is shown a cross sectional view of the molded core 33. FIG. 14 illustrates the core 33 after having its perimeter trimmed to define a core cup assembly wherein two cup forms 39-40 are provided and interconnected over the bridge region 41. The core 33 here is provided as a single unit. All of the layers of the core 33, except for the fabric layer 31, are preferably substantially coextensive and laminated with each other (except for the layer 31). Where underwire structures are provided at appropriate location (preferably the lower peripheral part) of the breast cups of the core, the foam panels 29 and 30 preferably remain substantially coextensive and laminated with each other.

The core 33 may then be engaged with the inner and outer panel assemblies 13 and 10. This may be achieved by a molding device consisting of two mold portions 45, 46 which each have surface relief features defining two cup forms. One or both of the panel assemblies 10 and 13 are preferably of a size which are sufficiently large to allow the assemblies 10 and 13 to provide the chest bands 2 extending from the breast cup regions 3. Such sufficient size may be provided by one or more layers of one or both of the inner and outer panel assemblies 13, 10. Alternatively, both the inner and outer panel assemblies 13, 10 extend only sufficiently to encase the core 33 and separate chest bands may be affixed to the core. Preferably, at least the foam panel 8 of the outer panel assembly 10 is of a size and shape sufficient to overlap the core 33. In this way, the perimeter of the core 33 is covered by the foam panel 8 and this helps improve visual concealment of this perimeter that may otherwise show through to the exterior of the bra.

In the molding of the core 33 with the inner and outer panel assemblies 10 and 13, the top mold is preferably at a temperature of approximately 180° and the bottom mold is preferably approximately 170°. The dwell time is preferably 120 seconds. While heat is applied to ensure lamination between the core 33 and the panels 10 and 13, the core 33 may be sprayed with an adhesive such as glue RM-30 of Ultra Energy Adhesive Trading Co. on both faces of the core.

In the most preferred form of the present invention, the core 33 comprises an underwire structure 25 interposed between two foam layers 29 and 30. The outer and inner panel assemblies 10 and 13 are substantially laminated with the core 33 on respective side (the outer and the inner side respectively) of the core. One or each of the outer and inner panel assemblies extends beyond at least a portion of the perimeter or boundary of the core 33 to form at least part of the chest bands 2. Additional layer(s) of material may optionally be applied, whether affixed or not, to the outer side of the outer panel assembly 10 and/or to the inner side of the inner panel assembly 13. The outermost layer of the bra extends beyond at least a portion of the perimeter or boundary of the core 33 to form at least part of the chest bands 2.

In a variation of the invention, one or both of the panel assemblies 10 and 13 may be formed to an appropriate molded shape prior to being engaged with the core 33. For example, the outer panel assembly 10 may be mold formed to an appropriate shape and subsequently engaged to the core 33. In this alternative arrangement, one or both of the panel assemblies 10 and 13 may or may not be fully laminated with the core 33. For example, the outer panel assembly 10 so formed may, instead of being fully surface laminated with the core 33, be engaged at least partly by edge engagement. For example, with reference to FIGS. 18 and 19, it can be seen that the outer panel assembly 10 is affixed to the core 33 by a hem 71. The affixing can be direct or indirect. The latter, i.e., indirect affixing, occurs when the hem 71 is affixed to, for example, the inner panel assembly 13. The affixing of the hem 71 is preferably by means of adhesive.

In FIG. 19, it can be seen that a hem 71 is provided by the outer panel assembly 10 that has been folded about part of the edge of the inner panel assembly 13. The hem 71 may be provided about the entire perimeter or about only part of the perimeter as for example shown in FIG. 19. Provision of the hem 71 is one mode of edge finishing of the bra of the present invention. An alternative mode is where the edge of the bra is ultrasonically welded. Any combination of ultrasonic welding and hem finishing may also be utilized. In the example of FIGS. 18 to 20, the outer panel assembly 10 defines the hem 71 at part of the perimeter, while ultrasonic welding is used to define the remainder of the perimeter.

In this variation, the outer panel assembly 10 preferably remains loose with respect to the core 33 except at the hem 71 and/or the ultrasonically welded part of the perimeter. However, the outer panel assembly 10 may be laminated to the core 33 or part thereof, and/or to the inner panel assembly 13. For example, lamination of the outer panel assembly 10 may occur with the inner panel assembly 13 at the chest bands 2, leaving the outer panel assembly 10 loose with respect to the core 33 at the breast cups 39 and 40. In the preferred form as described with reference to FIGS. 18 to 20, the outer panel assembly 10 is preferably of a single ply of fabric.

In the embodiment where the panel assemblies 10 and 13 are laminated with the core 33 on its respective sides, simultaneous molding and lamination of the core 33 with the panel assemblies 10 and 13 preferably occurs. The assembly of the panel assemblies 10 and 13 and the core 33 molded to the appropriate form can, after such molding and lamination, be trimmed to assume a form as, for example, shown in FIG. 16. Such trimming may occur manually or may be done ultrasonically by an ultrasonic machine such as device EGR-053 of Ever Green Ultrasonic Co., Ltd. and a trimming roller 28. The ultrasonic trimming device cuts and bonds the edge together at the same time. The core 33 is preferably of a perimeter smaller and inward of the trimmed perimeter of at least the outer panel assembly 10 and preferably also of the inner panel assembly 13. Accordingly the core 33 is captured within the panel assemblies 10, 13.

Where the variation as described with reference to FIGS. 18 to 20 occurs, the core 33 and the inner panel assembly 13 may be laminated together in the molding process as shown with reference to FIG. 15 and the outer panel assembly 10 may subsequently be affixed to the core 33. The outer panel assembly 10 may have been subjected to independent mold forming prior to affixing. Prior to the affixing of the outer panel assembly 10, the inner panel assembly 13 and/or the core assembly 33 may be perimeter trimmed to the appropriate shape and form. In this variation, the core 33 may have at least part of its perimeter coincident with part of the perimeter of the inner panel assembly 13, with the hem 71 covering any such coincident perimeter as a result of the hem being defined about such coincident perimeter.

FIG. 17 shows the peripheral region 50 of the bra through Section CC. It can be seen that the panel assemblies 10 and 13 are engaged to each other at the periphery and captured within the core 33. FIG. 20 shows a section through section DD of FIG. 19.

The peripheral components such as the fasteners 4, 5 and the shoulder straps may be fixed to the assembly shown in FIG. 16. The shoulder straps may be length adjustable and the fasteners may allow for adjustment of the band size of the bra. Such peripheral components are preferably engaged to the assembly shown in FIG. 16 by means of ultrasonic welding.

While reference has herein been made to the outer and inner panel assemblies 10 and 13 as comprising a layer of foam 8, 11 and a layer of fabric 9, 12, it may well be that either or both of the assemblies 10, 13 comprise only the fabric layer 9, 12. Indeed in the variation as described with reference to FIGS. 18 to 20 where a fully or partially hemmed perimeter is defined by the outer panel assembly 10, the assembly 10 is then a single ply of fabric material. The single ply of fabric material is preferably the ply 9 of fabric material previously described.

A further variation of the present invention is where the core 33 comprises only a single layer of foam material. In such a construction there may or may not be an underwire and/or the substantially non-stretchable layer 31 present. Alternatively, such components may be provided and interposed between one of the panel assemblies 10 or 13 and the core 33 consisting of a single layer of foam. Preferably, such components as the underwire assembly and/or the panel of substantially non-stretchable layer 31 are disposed between the single-foam core 33 and the inner panel assembly 13.

With reference to FIG. 23, there is shown a further variation of the present invention. Here, the primary structure of the bra is substantially as shown with respect to FIGS. 2 to 17, but an additional ply of material is provided on the outer side of the bra. The additional ply is the outermost ply 79 of the bra. The outermost ply 79 is preferably present for at least a substantial portion of the bra. The outermost ply 79 preferably overlaps the outer panel assembly 10 at least at the breast cups 39 and 40 and the bridge 41. The outermost ply 79 also preferably overlaps the outer panel assembly 10 at the chest bands 2. In the most preferred form, the outermost ply 79 defines the entire outermost surface of the bra of the present invention. However, a variation to that is as shown with reference to FIG. 24, in which the outermost ply 79 is shown not extending across the entire length of the chest bands 2 of the bra. The outermost ply 79 is preferably engaged by its hem 71 to a semi-finished or finished bra structure that is produced substantially with reference to FIGS. 2 to 17. The hem 71 is provided about the entire perimeter or a portion of the perimeter of the bra. With reference to FIG. 24, it can be seen that the hem 71 is provided about the lower region of the bra as well as around part of the underarm 80 and the neckline 81. The hem 71 is preferably affixed to the inner panel assembly 13. The hem 71 is preferably adhesively affixed to the inner panel assembly 13. It is preferably affixed to the fabric layer 12 of the inner panel assembly 13.

The outermost ply 79 is preferably not laminated or otherwise affixed to the outer panel assembly 10 and this has been shown in FIG. 25, in which a gap 82 may exist between the outermost ply 79 and the outer panel assembly 10. In such case, the outermost ply 79 is loose with respect to the outer panel assembly 10 or indeed the core 33.

The outermost ply 79 is preferably fabric. It can be or can include a lace, or may include sections that are lace. Alternatively, or in addition, the outermost ply 79 may include non-laced fabric or other materials.

In an embodiment where the outermost ply 79 is lace or substantially lace, it may require a perimeter strip 86 at or covering the hem 71 to facilitate the bonding of the hem 71 with the inner panel assembly 13. The strip 86 is preferably of a fabric material, or it can be other tape which allows for adhesive and/or heat bonding to occur. The strip 86 can be applied to cover or overlap the hem 71, with or without at the same time overlapping a portion of the fabric layer 12 of the inner panel assembly 13, to facilitate bonding of the hem 71 to the inner panel assembly 13. FIG. 25 has not shown the strip 86 extending to cover also a portion of the inner panel assembly 13, but it is possible and preferable to have the strip 86 covering not only the hem, but also extending to cover and overlap a portion of the inner panel assembly.

The outer panel assembly 10 preferably provides its foam layer 8 to overlap at least the perimeter of the core 33, in order to reduce the visibility of the perimeter of the core assembly 33 to the exterior of the bra. Similarly the inner panel assembly 13 preferably provides its foam layer 11 to overlap at least the perimeter of the core 33.

With reference to FIG. 21, there is shown a further item that may be included intermediate of the two foam layers 29 and 30 of the core assembly or core 33. In FIG. 21 the core assembly 33 incorporates a pouch 72 that may include a liquid. The pouch is shown in more detail in FIG. 22 wherein the pouch includes a containment region 73 that is sealed by the perimeter seal 74. The containment region 73 may include a liquid. Examples of suitable liquid include water, oil, gel, or any liquid having preferably a greater viscosity than water. The pouch 72 is preferably incorporated between the foam layers 29 and 30 of the core assembly 33. It can be provided to enhance the appearance of the bra or the appearance of the breasts of the wearer of the bra. The volume of the containment region 73 and/or the volume of liquid contained therein can be so set as to achieve the result desired by individual tastes. In the embodiment as shown in FIGS. 21 and 22 an underwire assembly 25 is included positioned adjacent and below the pouch 72.

While the present invention has been described with reference to particular embodiments thereof, it will be understood that such embodiments are susceptible of modifications and variations without departing from the scope of the present invention and that the invention will include all embodiments falling within the scope of the appended claims. 

1. A brassiere comprising: a core defining at least two breast cups of the brassiere, the core comprising a first layer of foam material, a second layer of foam material that is substantially laminated with the first layer of foam material, and an underwire located between the first and second layers of foam material at or adjacent the lower peripheral part of one or each of the two breast cups; and a first and a second covering layer, each covering layer comprising at least a fabric ply and each covering layer being laminated with the core on a respective side of the core to encase the core.
 2. A brassiere as claimed in claim 1 wherein the core has been subjected to molding to form the shape of the two breast cups.
 3. A brassiere as claimed in claim 1 wherein the core does not define any chest band of the brassiere.
 4. A brassiere as claimed in claim 1 wherein one or each of the first and second layers of foam material is a continuous layer extending across the core.
 5. A brassiere as claimed in claim 1 wherein the underwire comprises a rigid elongate member and a channel encasing the rigid elongate member.
 6. A brassiere as claimed in claim 5 wherein the channel is a fabric material.
 7. A brassiere as claimed in claim 6 wherein the first and second layers of foam material have mutually facing surfaces and the channel is adhered to one or each of the facing surfaces of the first and second layers of foam material by an adhesive.
 8. A brassiere as claimed in claim 1 wherein the underwire is a non-metallic strip.
 9. A brassiere as claimed in claim 1 wherein the core has a perimeter and one or each of the first and second covering layers extends beyond at least a portion of the perimeter of the core to form at least part of a chest band of the brassiere.
 10. A brassiere as claimed in claim 1 wherein the first covering layer comprises a fabric ply and a foam ply, the fabric ply and the foam ply being laminated to each other.
 11. A brassiere as claimed in claim 10 wherein a surface of the core is laminated to the foam ply of the first covering layer.
 12. A brassiere as claimed in claim 1 wherein the second layer of foam material is laminated to the first layer of foam material by an adhesive.
 13. A brassiere as claimed in claim 1 wherein the core further defines a bridge between the two breast cups, and wherein a flexible and substantially non-stretchable panel of material is located between the first and second layers of foam material and laminated with one or each of the first and the second layers of foam material at the bridge.
 14. A brassiere as claimed in claim 1 wherein the core has a perimeter and the brassiere further comprises an outermost layer that is at a greater distance from the body of the wearer of the brassiere than either of the first and the second covering layers, the outermost layer extending beyond at least a portion of the perimeter of the core to form at least part of a chest band of the brassiere.
 15. A brassiere as claimed in claim 14 wherein the brassiere has an inner surface and the outermost layer has a perimeter, the outermost layer being folded at at least a portion of its perimeter to provide a hem affixed to at least a portion of the inner surface of the brassiere.
 16. A brassiere as claimed in claim 15 wherein the hem is affixed to at least a portion of the perimeter region of the inner surface of the brassiere.
 17. A brassiere as claimed in claim 15 wherein one of the first and second covering layers is at least part of the inner surface of the brassiere.
 18. A brassiere as claimed in claim 15 wherein the brassiere further comprises a strip of fabric material that is affixed to at least a portion of the hem and at least a portion of the inner surface of the brassiere.
 19. A brassiere as claimed in claim 14 wherein the outermost layer includes a lace fabric.
 20. A brassiere as claimed in claim 15 wherein the hem is affixed adhesively to at least a portion of the inner surface of the brassiere.
 21. A brassiere as claimed in claim 14 wherein the outermost layer is not laminated to at least one of the first and second covering layers.
 22. A brassiere as claimed in claim 1 wherein the core further comprises a pouch located between the first and second layers of foam material at or adjacent a lower portion of one or each of the two breast cups, the pouch containing a material selected from one of a liquid and a gel.
 23. A brassiere as claimed in claim 22 wherein the pouch is laminated to one or each of the first and second layers of foam material.
 24. A brassiere as claimed in claim 1 wherein the brassiere is seamless.
 25. A brassiere comprising: a core having a perimeter and defining at least two molded breast cups of the brassiere, the core comprising an outer layer of foam material, an inner layer of foam material that is substantially laminated with the outer layer of foam material, and an underwire interposed between the outer and inner layers of foam material at or adjacent the lower peripheral part of one or each of the two breast cups; an outer and an inner covering layer, each covering layer comprising a fabric ply and a foam ply which are substantially laminated to each other, the foam ply of each covering layer being substantially laminated with the core on a respective side of the core to encase the core; and wherein one or each of the outer and inner covering layers extends beyond at least a portion of the perimeter of the core to form at least part of a chest band of the brassiere.
 26. A brassiere as claimed in claim 25 wherein the core further comprises a pouch located between the outer and inner layers of foam material at or adjacent a lower portion of one or each of the two breast cups, the pouch containing a material selected from one of a liquid and a gel.
 27. A brassiere as claimed in claim 25 wherein the brassiere further comprises an outermost layer that is at a greater distance from the body of the wearer of the brassiere than either of the outer and the inner covering layers, the outermost layer extending beyond at least a portion of the perimeter of the core to form at least part of a chest band of the brassiere.
 28. A brassiere as claimed in claim 25 wherein the brassiere is seamless. 